IMPORTANT NOTE TO THE INSTALLERThe Albion Aerocyl Cylinder is specifically designed to be installed in conjunction with a Heat Pump, or a Solar thermal system and additional input from a Heat Pump. Connection to any other form of heat appliance or boiler is not acceptable.

Read these instructions before commencing installation. Unvented cylinders are a controlled service as defined in the latest edition of the building regulations and should only be fitted by a competent person.

The relevant regulations are: England and Wales – Building Regulation G3, Scotland – Technical Standard P5, N Ireland – Building Regulation P5

After installation the Benchmark Log Book must be completed and left, with these instructions, with the householder for future reference.

INSTALLATION INSTRUCTIONS FOR ALBION AEROCYL UNVENTED COPPER CYLINDERS: HEAT PUMP ONLY OR HEAT PUMP AND SOLAR INPUT MODELS

Issue 03 March 2011Part No. BOOKAEROCYL

Unvented Copper Hot Water Cylinders

Page 1 of 16

INTRODUCTIONThe Aerocyl Unvented cylinder is made from Copper for excellent corrosion resistance.

Aerocyl has a strong rust-proofed steel case and is highly insulated with environmentally friendly foam.It is available in 5 capacities from 150 – 300 litres in Heat Pump Only versions. Solar input models are available in 4 capacities from 180 - 300 litres.Aerocyl is supplied complete with all the necessary safety and control devices needed to connect to the cold water mains. All are pre-adjusted. High quality controls have been selected to combine high flow rate performance with minimum pressure drop to

make Aerocyl perform well in all areas, even those with poor water pressure. Aerocyl is WRAS approved to show compliance with Building Regulations G3+L.

STORAGE PRIOR TO INSTALLATIONAerocyl should be stored in its original packaging in an upright position in an area free from excessive damp.

Expansion Vessel150 ltr units - 12 ltr vessel

180, 210 & 250 ltr units - 19 ltr vessel300 ltr units - 24 ltr vessel

15/22mm Tundish

Expansion Vessel Hose Wall Mounting Kit forExpansion Vessel

Temperature and PressureRelief Valve

Dual Thermostat High Flow RateInlet Control Set

Two Port Valve

Incoloy long life 240V x3kW Immersion Heater

Installation &MaintenanceInstructions

BenchmarkLog Book

UNPACKING THE UNIT

Page 2 of 16

Heat Pump Only Models• Inlet control set.• Temp & Pressure relief valve.• 15mm / 22mm Tundish.• Expansion vessel.• Wall mounting bracket.• Expansion vessel hose.• 1 x 3kW Immersion Heater (2 x 3kW 240V on 250 & 300 litre units).• Two port zone valve.• Dual Thermostat.• Installation & Maintenance Instructions.• Benchmark Log Book.

Heat Pump and Solar Input Models• Inlet Control set.• Temp & Pressure relief valve.• 15mm / 22mm Tundish.• Expansion vessel.• Wall mounting bracket.• Expansion vessel hose.• Immersion Heater.(2 x 3kW 240V on 250 & 300 litre units).• 2 x Two port valves.• 1 x Dual Thermostat.• 1 x Single Control stat.• 1 x Single High limit stat.• Installation & Maintenance Instructions.• Benchmark Log Book.• 2 x Sensor pocket retaining bungs.

AEROCYL COMES COMPLETE WITH ALL THE FITTINGS YOU NEED TO COMPLETE THE INSTALLATION:

IMPORTANT NOTE TO THE

INSTALLERThe Albion Aerocyl Cylinder is

specifically designed to be installed in

conjunction with a Heat Pump, or a Solar

thermal system and additional input

from a Heat Pump. Connection to any

other form of heat appliance or boiler

is not acceptable.Read these instructions before

commencing installation. Unvented

cylinders are a controlled service as

defined in the latest edition of the building

regulations and should only be fitted by a

competent person.

The relevant regulations are: England

and Wales – Building Regulation G3,

Scotland – Technical Standard P3, N Ireland –

Building Regulation P5After installation the Benchmark Log

Book must be completed and left, with

these instructions, with the householder

for future reference.

INSTALLATION INSTRUCTIONS FOR ALBION AEROCYL

UNVENTED COPPER CYLINDERS: HEAT PUMP ONLY

OR HEAT PUMP AND SOLAR INPUT MODELS

Issue 03 March 2011

Part No. BOOKAEROCYL

Page 1 of 16

MAINS PRESSURE HOT WATER STORAGE SYSTEM COMMISSIONING CHECKLIST

* All installations in England and Wales must be notified to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme.

A Building Regulations Compliance Certificate will then be issued to the customer.

©Heating and Hotwater Industry Council (HHIC)

www.centralheating.co.uk

ALL SYSTEMS PRIMARY SETTINGS (indirect heating only)

Is the primary circuit a sealed or open vented system?

Sealed

Open

What is the maximum primary flow temperature?

°C

ALL SYSTEMS

What is the incoming static cold water pressure at the inlet to the system?

bar

Has a strainer been cleaned of installation debris (if fitted)?

Yes

No

Is the installation in a hard water area (above 200ppm)?

Yes

No

If yes, has a water scale reducer been fitted?

Yes

No

What type of scale reducer has been fitted?

What is the hot water thermostat set temperature?

°C

What is the maximum hot water flow rate at set thermostat temperature (measured at high flow outlet)?

l/min

Time and temperature controls have been fitted in compliance with Part L of the Building Regulations?

Yes

Type of control system (if applicable)

Y Plan

S Plan

Other

Is the cylinder solar (or other renewable) compatible?

Yes

No

What is the hot water temperature at the nearest outlet?

°C

All appropriate pipes have been insulated up to 1 metre or the point where they become concealed

Yes

UNVENTED SYSTEMS ONLY

Where is the pressure reducing valve situated (if fitted)?

What is the pressure reducing valve setting?

bar

Has a combined temperature and pressure relief valve and expansion valve been fitted and discharge tested?

Yes

No

The tundish and discharge pipework have been connected and terminated to Part G of the Building Regulations

Yes

Are all energy sources fitted with a cut out device?

Yes

No

Has the expansion vessel or internal air space been checked?

Yes

No

THERMAL STORES ONLY

What store temperature is achievable?

°C

What is the maximum hot water temperature?

°C

ALL INSTALLATIONS

The hot water system complies with the appropriate Building Regulations

Yes

The system has been installed and commissioned in accordance with the manufacturer’s instructions

Yes

The system controls have been demonstrated to and understood by the customer

Yes

The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer

Yes

Commissioning Engineer’s Signature

Customer’s Signature

(To confirm satisfactory demonstration and receipt of manufacturer’s literature)

This Commissioning Checklist is to be completed in full by the competent person who commissioned the storage system as a means of

demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.

Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.

Customer Name

Telephone Number

Address Cylinder Make and Model

Cylinder Serial Number

Commissioned by (print name)

Registered Operative ID Number

Company Name

Telephone Number

Company Address

Commissioning Date

To be completed by the customer on receipt of a Building Regulations Compliance Certificate* :

Building Regulations Notification Number (if applicable)

WATER SUPPLYAerocyl operates at 2.1 bar (controlled by the inlet control set) and is capable of delivering over 50 litres per minute. The high quality inlet control set has been designed to make the most of the flow rates available however the performance of any Unvented system is only as good as the mains water supply. The maximum possible water demand should be assessed taking into consideration that both hot and cold services are supplied simultaneously from the mains.

The water supply should be checked to ensure it can meet these requirements. If necessary consult the local water company regarding the likely pressure and flow rate availability.

If measuring the water pressure note that a high static (no flow) mains pressure is no guarantee of good flow availability. In a domestic installation 1.5 bar and 25 l/min. should be regarded as the minimum. The maximum mains pressure the inlet control set can cope with is 12 bar.

Consideration should be given to upgrading existing ½” (15mm) cold mains pipework to a larger size if the recommended minimum pressure/flowrate is not being achieved.

SITING THE UNITAerocyl can supply outlets above it or at some distance from it. Site the unit to minimise “dead leg” distances especially to the point of most frequent use.

Outlets above the Aerocyl will reduce the outlet pressure available by 0.1 bar for every 1m of height difference. The unit should be protected from frost. Particular care is needed if siting in a garage or outbuilding. All exposed pipework should be insulated. Aerocyl must be installed VERTICALLY on a flat base capable of supporting the weight of the cylinder when full (see technical specification section for weights p14). The minimum recommended cupboard size is 650mm square.

Access for maintenance of the valves should be considered. Consideration should be given to position of discharge pipes (tundish), drain valves, motorised valves, shall be positioned away drom electrical components.The immersion heaters are 375mm long and care should be taken that they can be withdrawn for servicing if required. The discharge pipework from the safety valves should fall continuously and terminate safely.

SCHEMATIC DIAGRAM

IMMERSIONHEATER

COLDMAIN

ISOLATINGVALVE

PRESSUREREDUCINGVALVE

EXPANSIONVESSELWITH WALL BRACKET

FLEXIBLEHOSE

NON RETURN

VALVE

EXPANSIONRELIEFVALVE

TUNDISH

TEMPERATURE& PRESSURERELIEF VALVE

BALANCEDCOLD CONNECTION

COLDINLET VIADRAIN

NON RETURNVALVE

BRONZEPUMP

SECONDARY RETURN CIRCUIT( 210, 250 & 300 L SIZES )

DUALSTAT2 PORT

VALVE

HEAT PUMPFLOW

HEAT PUMP RETURN

HOT OUTLET

Notes: The Pressure reducing valve, Non return valve and Expansion relief valve are combined together in the inlet control set. On 150 – 180 litre sizes there is no dedicated secondary return boss and the secondary return circuit should be tee’d into the cold feed pipe just above the drain elbow

Page 3 of 16

COLD MAINS PIPEWORKRun the cold main through the building to the place where the Aerocyl is to be installed. Take care not to run the cold pipe near hot water or heating pipe work so that the heat pick-up is minimized. Identify the cold water supply pipe and fit an isolating valve (not supplied) A 22mm BS1010 stopcock can typically be used but a 22mm quarter turn full bore valve would be better as it does not restrict the flow as much. Do not use “screwdriver slot” or similar valves. Make the connection to the cold feed of the cylinder and incorporate a drain valve. Position drain vale no higher than the cold inlet to ensure sufficient draining of cylinder when required. Position the inlet control just ABOVE the Temperature & Pressure Relief Valve (TPRV) mounted on the side of the cylinder. This ensures that the cylinder does not have to be drained down in order to service the inlet control set. Ensure that the arrow points in the direction of the water flow. Select a suitable position for the expansion vessel. Mount it to the wall using the bracket provided. Use the hose to connect to the inlet control group.

CONNECTING TO THE CYLINDERAll of the pipework connections on the cylinder are 22mm compression and supplied complete with gland nuts and olives, in the Accessory Kit Box. Only connect 22mm Table X copper tube to these connections.Cut the tube with a pipe cutter and ensure no sharp edges or burrs protrude. Slide both gland nut and olive onto the tube and push tube fully home into the connection, ensuring the tube end fully bottoms on the connection recess.Smear the outer wall of the olive with plumbing paste and tighten gland nut in the prescribed manner. Upon filling/commissioning, ensure all connections are completely watertight. Note: No control or isolation valve should be fitted between the expansion relief valve and the storage cylinder. The relief valve connections should not be used for any other purpose.

BALANCED COLD CONNECTIONIf there are to be showers, bidets or monobloc taps in the installation then a balanced cold supply is necessary. There is a 22mm balanced connection on the inlet control set.

HOT WATER PIPEWORKRun the first part of the hot water distribution pipework in 22mm. This can be reduced to 15mm and 10mm as appropriate for the type of tap etc. Your aim should be to reduce the volume of the hot draw off pipework to a practical minimum so that the time taken for the hot water is as quick as possible. Where monobloc mixing taps and showers are used, these should be installed to comply with the Water Supply (Water Fittings) Regulation 1999. If these devices are supplied with un-balanced supplies there should be single check valves installed at both inlets, to stop over pressurising of either supply. Select a suitable position for the expansion vessel. Mount it to the wall using the bracket provided and connect to the inlet control set with the flexible hose provided. Ensure that the top of the vessel is accessible for servicing.

PRIMARY COIL CONNECTIONSFor Solar input models refer to pages 10-13 before making any connections.Connect the primary connections using the compression connections provided. The primary circuit must be positively pumped. Gravity circulation is not suitable. Either primary connection may be used as the primary flow. Reheat times are identical either way. The primary circuit can be open vented or sealed with up to a maximum pressure of 3.5 bar. If you seal the primary circuit an additional expansion vessel and safety valve is required. The Heat Pump must operate under effective thermostatic control. Uncontrolled heat sources are NOT SUITABLE. Please contact our technical department for guidance. Connect the two port zone valve into the primary flow pipework. The direction of flow arrow should be towards the primary flow connection. On twin coil solar input cylinders we have provided an extra thermostat boss should you wish to use it.

SECONDARY CIRCULATIONAerocyl can be used with secondary circulation. An appropriate WRAS approved bronze circulator should be used in conjunction with a non return valve to prevent backflow. On large secondary circulation systems it may be necessary to incorporate an extra expansion vessel into the circuit to accommodate the increased system water volume. A secondary return boss is fitted as standard on 210, 250 & 300L. On smaller sizes tee into the cold feed pipe above the drain.

IMMERSION HEATERSOnly immersion heaters with a thermal cutout may be used. To help ensure this the immersion heaters have a special 2¼” BSP thread. They are rated at 3 kW at 240 V and are of a low noise Incoloy construction. They have both a thermostat and a high limit cutout. Please order the correct replacement via ourselves, fitting non-approved immersions may affect your guarantee. When fitting, ensure the ‘O’ ring is positioned correctly on the head of the immersion heater and lubricate before fitting. Fit it by hand until almost home then tighten gently as the ‘O’ rings will seal easily. The electrical supply to each immersion heaters must be fused at 13A via a double pole isolating switch to BS 3456. The cable must be at least 2.5mm2 heat resistant (85°C HOFR) sheathed flex complying to BS 6141:1981 Table 8. Do not operate the immersion heater/s until the unit is full of water. Do not operate the immersion heater/s if any sterilisation liquid is in the cylinder as this will cause premature failure. Fit the immersion thermostat into the thermostat pocket. Complete the wiring – use the appropriate wiring diagrams on page 6.

GENERAL INSTALLATION

Page 4 of 16

(expansion vessel not to scale)

Expansion VesselConnection at rear of valve(Remove 3/4” Plug)

Turn to testCold

Mains In

Balanced Cold Connection

Outlet to Cyclinder

ExpansionRelief toTundish

Expansion Relief Connection

DISCHARGE ARRANGEMENT

Note: The discharge will consist of scalding water and steam. Asphalt, roofing felt and non-metallic rainwater goods may be damaged by such discharges.

Note: D2 pipe from tundish is now allowed to be installed in soil stacks within premises. This activity is not recomended by Kingspan as discharge from T&P may continue for long periods of time. It is the installers responsibility to ensure the discharge pipework can support the discharge for prolonged periods. If used follow guidance on mechanical seal without water trap given in G3 Building Regulations.As discharge can be in excess of 90oC discharge into plastic pipework is also not recommended.

Position the inlet control group so that the discharge from both safety valves can be joined together via a 15mm end feed Tee (see diagram above). Connect the Tundish and route the discharge pipe. The discharge pipework must be routed in accordance with Part G3 of schedule 1 of the Building Regulations. The information that follows is not exhaustive and if you are in doubt you should seek advice. The two safety valves will only discharge water under fault conditions. When operating normally water will not be discharged. The tundish should be vertical, located in the same space as the unvented hot water storage system and be fitted as close as possible to, and lower than, the safety device, with no more than 600mm of pipe between the valve outlet and the tundish. Any Discharge should be visible at the tundish.The tundish should be located such that any discharge is visible. In addition, where discharges from safety devices may not be apparent, e.g. people with impared vision or mobility, consideration should be given to the installation of a suitable safety device to warn when discharge takes place, e.g. electronically operated.

The discharge pipe (D2) from the tundish should:

A) Have a vertical section of pipe at least 300mm long, below the tundish before any elbows or bends in the pipework.B) Be installed with a continuous fall of at least 1 in 200 thereafter.

The discharge pipe (D2) from the tundish should be of metal or other material that have been demonstrated to be capable of withstanding temperatures of the water discharged.

The discharge pipe (D2) should be at least one pipe size larger than the nominal outlet size of the safety device unless its total equivalent hydraulic resistance exceeds that of a straight pipe 9m long i.e. discharge pipes between 9m and 18m equivalent resistance length should be at least two sizes larger than the nominal outlet size of the safety device, between 18 and 27m at least 3 sizes larger, and so on. Bends must be taken into account in calculating the flow resistance. Refer to diagram 1, Table 1 and the worked example. An alternative approach for sizing discharge pipes would be to follow BS6700 Specification for design installation, testing and maintenance of services supplying water for domestic use within buildings and their curtilages.

The discharge pipe (D2) should terminate in a safe place where there is no risk to persons in the vicinity of the discharge. Examples of acceptable discharge arrangements are:a. To a trapped gully with the end of the pipe below the fixed grating and above the water seal.b. Downward discharges at a low level; i.e. up to 100mm above external surfaces such as car parks, hard standings, grassed areas etc. are acceptable providing that where children play or otherwise come into contact with discharges, a wire cage or similar guard is positioned to prevent contact whilst maintaining visibility.c. Discharges at a high level; e.g. in to metal hopper and metal down pipe with the end of the discharge pipe clearly visible or onto a roof capable of withstanding high temperature discharges of water and 3m from any plastic guttering systems that would collect such discharges.d. device to warn when discharge takes place.

WORKED EXAMPLEThe example below is for G1/2 temperature relief valve with a discharge pipe (D2) having 4 No. elbows and length of 7m from the tundish to the point of discharge.From Table 1:Maximum resistance allowed for a straight length of 22mm copper discharge pipe (D2) from a G1/2 temperature relief valve is: 9.0m. Subtract the resistance for 4 No. 22mm elbows at 0.8m each = 3.2m. Therefore the maximum permitted length equates to: 5.8m. 5.8m is less than the actual length of 7m therefore calculate the next largest size. Maximum resistance allowed for a straight length of 28mm pipe (D2) from a G1/2 temperature relief valve equates to: 14m. As the actual length is 7m, a 28mm (D2) copper pipe will be satisfactory.

Table1Sizing of copper discharge pipe ‘D2’ for a temperaturerelief valve with a G1/2 outlet size (as supplied).

Size ofdischargepipework

Maximum length of straight pipe(no bends or elbows)

Deduct the figure belowfrom the maximum length for each bend or elbow in the discharge pipe

22mm Up to 9m 0.8m

28mm Up to 18m 1m

35mm Up to 27m 1.4m

Page 5 of 16

Diagram of a typical discharge pipe arrangement (extract from Building Regulation G3)

WIRING DIAGRAM 2 x TWO PORT ZONE VALVES (S-PLAN)

TYPICAL SCHEMATIC WIRING DIAGRAM

VARIANT DUAL THERMOSTAT WIRING

WIRING DIAGRAM THREE PORT MID POSITION VALVE (Y-PLAN) + TWO PORT VALVEVARIANT DUAL THERMOSTAT WIRING

The diagrams shown relate to the components listed. Other components and other manufacturers’ components may vary in their wiring requirements, particularly thermostats. Always refer to manufacturers’ instructions which may override this detail in order to function correctly.

WHE

RE T

HE P

ROGR

AMME

R IS

IN-B

UILT

TO

THE

HEAT

PUM

P RE

FER

TO M

ANUF

ACTU

RERS

WIR

ING

DETA

IL

Page 6 of 16

COMMISSIONINGFLUSHING & FILLING THE CYLINDERCheck the pressure in the expansion vessel is 2.1 bar (30PSI), i.e. the same as the setting of the pressure reducing valve. The valve is of the car tyre (Schrader) type. Check all the connections for tightness including any factory made connections such as the immersion heater and the temperature and pressure relief valve. Before filling, open the hot tap furthest away from the Aerocyl to let air out. Open the cold main isolation valve and allow the unit to fill. When water flows from the tap allow it to run for a short while to flush through any dirt, swarf or flux residue. Close the tap and open every other hot tap in turn to purge all remaining air.

PRIMARY CIRCUITConsult the Heat Pump manufacturers commissioning instructions and fill the primary circuit. Ensure the lever on the two port valve is set to the filling position. When full, move the lever back. Switch the programmer to Domestic Hot Water (DHW) and allow the unit to start to heat. Adjust the dial of the dual thermostat to between 55°C and 65°C as required.

STORAGE TEMPERATUREThe recommended storage temperature is 60-65°C. In hard water areas consideration should be given to reducing this to 55°C. In many healthcare applications the guidance on Legionella control and safe water delivery temperatures will require storing the water at 60-65°C, distributing at 50- 55°C and using thermostatic mixing valves to control the final temperature.For details consult the NHS Estates Guidance on safe hot water temperatures.

SAFETY VALVE CHECKSDuring heat-up there should have been no sign of water coming from either the expansion relief valve or the temperature / pressure relief valve. Now hold both of these safety valves fully open allowing as much water as possible to flow through the tundish. Check that your discharge pipework is free from debris and is carrying the water away to waste efficiently. Release the valves and check that they reseat properly. On completion of commissioning, fill in the Log book and leave with the house owner.

SERVICINGGENERALServicing should only be carried out by competent installers and any spare parts used must be purchased from Albion. NEVER bypass any safety devices or operate the unit without them being fully operational.

DRAININGIsolate from the electrical supply to prevent the immersion heaters burning out. Isolate the unit from the cold mains. Attach a hose to the draining tap ensuring it reaches to a level below the unit (This will ensure an efficient syphon is set up and the maximum amount of water is drained from the unit). Open the hot tap closest to the unit and open the draining tap. WARNING: WATER DRAINED OFF MAY BE VERY HOT!

ANNUAL MAINTENANCEAerocyl requires an annual service in order to ensure safe working and optimum performance. It is essential that the following checks are performed by a competent installer on an annual basis.

1) Twist the cap of the expansion relief valve on the inlet control set and allow water to flow for 5 seconds. Release and make sure it resets correctly. Repeat with the pressure / temperature relief valve. In both cases check that the discharge pipework is carrying the water away adequately. If not, check for blockages etc. and clear. WARNING: THE WATER DISCHARGED MAY BE VERY HOT!2) Check that any immersion heaters fitted are working correctly and that they are controlling the water at a temperature between 55°C and 65°C.3) Check the pressure in the expansion vessel is charged to 2.1 bar. Turn off the water supply to the unit and open a hot tap first. The air valve on expansion vessel is a Schrader (car tyre ) type. Air or CO2 may be used to charge the expansion vessel.4) Unscrew the head on the inlet control set and clean the mesh filter within.5) The Benchmark Log Book supplied with this unit should be updated at each service.

YOUR GUARANTEE MAY BE VOID WITHOUT PROOF OF ANNUAL SERVICING

SPARE PARTSWe carry the full range of spares listed below in stock. If you order before noon we will dispatch the same day for delivery the next to most locations. Tel: 01924 376026.

CONSETALT22 - Inlet control set (pressure reducing valve, strainer and expansion relief valve) 2.1 BAR/3 BAR.VALVETP1/24 - Temperature & pressure relief valve 4 BAR/90ºCTUNDPL15ALT - TundishVALVE2PORT - 2 port valveSTATDUALALT - Dual thermostatIMHTRANI - Immersion heater ( same on all models )EXPVES1221 - 12 litre Expansion Vessel (150 litre size)

EXPVES1921 - 19 Litre Expansion vessel ( 180 , 210 & 250 ltr sizes)EXPVES2421 - 24 litre expansion vessel ( 300 ltr size )EXPVBRKALTS - Wall mounting bracketFLEXHOSEALT - Expansion vessel hose ( ¾” M x ¾” F )STATSGLALT – Single control statSTATHIGHALT – Single high limit statPOCKETSSBUNG – Sensor pocket retaining bungs

Page 7 of 16

FAULT FINDING

Page 8 of 16

PRODUCTCODE

CAPACITY(Litres)

HEIGHT DIAMETER A B C D I E F G H WEIGHT(Kg - EMPTY)

WEIGHT(Kg-FULL)

*kW RATING

AAU150C 150 1128 550 450 425 135 650 515 863 N/F N/F 57 207 23.3

AAU180C 180 1322 550 450 425 135 650 515 1057 N/F N/F 61 241 28.3

AAU210C 210 1515 550 450 425 135 650 515 1250 1100 N/F 64 274 28.1

AAU250C 250 1772 550 450 425 135 650 515 1508 1350 1195 77 327 27.4

AAU300C 300 2096 550 450 425 135 650 515 1831 1706 1515 93 393 26.7

All dimensions are in mm and are of the cased unit. N/F = not fitted*kW rating of coil when tested in accordance with BS EN 12897

Aerocyl Heat Pump Only

Technical Specifications

Page 9 of 16

A B

C

D I EG FH

22mm HOTDR AW - OFF “

F PTRV BOSS

SECONDIMMERSION HEATER(not always �tted. See table)

22mm SECONDARYRETURN (not always �tted. See table)

12/

G DH E IA B

C

F

70 O

50 O

40 O

30 O40 O

20 O

A B

C

D I EG FH

22mm HOTDR AW - OFF “

F PTRV BOSS

SECONDIMMERSION HEATER(not always �tted. See table)

22mm SECONDARYRETURN (not always �tted. See table)

12/

G DH E IA B

C

F

70 O

50 O

40 O

30 O40 O

20 O

AEROCYL UNVENTED COPPERCYLINDER: SOLAR INPUT

These models are specifically designed to be installed with input from solar panels and the Heat Pump:

It is essential the overall installation meets all current legislation including, in particular, the high limit isolation requirements of Building Regulation G3. This document is designed to assist in achieving this aim.

UPPER COILThe upper coil is connected to the Heat Pump as per the instructions on page 4, with the Danfoss ITD100 control and high limit thermostat inserted into pocket M (see diagram page 12). The wiring requirements are as depicted on page 11.

LOWER COILThe lower coil is connected to the solar heat source. Either primary coil connection may be utilised as the flow or return. The solar cylinder sensor, supplied as part of the solar controls, inserts into pocket D (see page 12). It is necessary to mount the solar pump in the return pipework with the Danfoss HP22 two port valve (supplied with the cylinder) installed between the cylinder and the pump. This valve is of the powered open, sprung closed design and is wired through the ITL100 high limit stat which inserts into pocket J (see page 12). Two wiring options for high limit isolation are provided in Fig. 1 and Fig. 2 page 11. The Danfoss ITC100 control thermostat is not required in a solar installation but a control thermostat should be connected to the solar pump control device to stop circulation of the solar fluid. Refer to Solar instalation guide for instructions on connections.

Page 10 of 16

TYPICAL SCHEMATIC WIRING DIAGRAMS.SOLAR HIGH LIMIT CONTROLThese schematic wiring diagrams depict an IMIT high limit control stat and the connections are numbered accordingly. Where an alternative is supplied connect as per manufacturers’ instructions.

Page 11 of 16

All dimensions are in mm and are of the cased unit. N/F = not fitted

Aerocyl Heat Pump and Solar Input

PRODUCTCODE

CAPACITY(Litres)

HEIGHT DIAMETER A B C D E F G H& M I JKL WEIGHT(Kg - EMPTY)

WEIGHT(Kg-FULL)

kW RatingLOWER

COIL

kW RatingUPPER COIL

AAUS180C 180 1322 550 135 225 335 355 840 865 915 955 N/F 1057 65 245 22.7 34.1

AAUS210C 210 1515 550 135 225 335 355 905 930 980 1020 1150 1250 68 278 21.5 31.9

AAUS250C 250 1772 550 135 225 335 355 1065 1090 1140 1180 1400 1507 81 331 21.1 33

AAUS300C 300 2096 550 135 225 335 355 1130 1155 1205 1245 1600 1830 97 397 20.5 33.6

Technical Specifications

J I H

F EI D

M BCG

C

B

F

A

E

A

J,K,L

D

K

22mm HOTDR AW - OFF “ F PTRV BOSS

IMMERSION HEATER

22mm SECONDARYRETURN (not always �tted. See table)

H&M G

70 O

50 O

40 O

30 O40 O

20 O L

½

J I H

F EI D

M BCG

C

B

F

A

E

A

J,K,L

D

K

22mm HOTDR AW - OFF “ F PTRV BOSS

IMMERSION HEATER

22mm SECONDARYRETURN (not always �tted. See table)

H&M G

70 O

50 O

40 O

30 O40 O

20 O L

½

Page 12 of 16

Aerocyl Solar input cylinders are designed to accept heat input from a renewable/sustainable (i.e: Solar) heat source.Where this input does not fully meet the desired temperature a guaranteed quantity of water can be heated to an acceptable temperature by the heat pump or immersion heater.The Domestic Heating Compliance Guide document L1A and L1B provides excellent advice in sizing both cylinder designated solar areas and heat exchangers to the surface area of the solar collectors. Using this guide Albion are able to offer sizing advice for specification.

Water Capacities (litres)Model Designated Solar Area Heat Pump Area Total CapacityAAUS 180C 55 125 180

AAUS 210C 65 145 210

AAUS 250C 90 160 250

AAUS 300C 100 200 300

Lower (Solar) Coil SpecificationModel Surface Area (m2) Fluid Content (litres)AAUS 180C 0.963 2.355

AAUS 210C 0.963 2.355

AAUS 250C 0.963 2.355

AAUS 300C 0.963 2.355

Insulation Detail

NB: The total detail of compliance guide document should be consulted prior to specifying product or commencing design.

In addition our insulation process offers benefits to the ‘green’ specifier.Polyurethane foam, nominal thickness 50mm.The foam is CFC-Free and HCFC-Free.Ozone Depletion Potential (ODP) ZEROGlobal Warming Potential (GWP) ONE

Albion Aerocyl Solar input cylinders have been designed specifically with Solar applications complimenting the heat pump. Featuring a purpose-designed solar coil, which allows maximum heat transfer of solar energy into the stored water, the cylinders are suitable for use with a wide range of solar systems now available in the UK and are an efficient and environmentally friendly way of providing Domestic Hot Water. Aerocyl Solar input cylinders also offer the benefit of mains pressure hot water – powerful showers and fast filling baths.

Aerocyl Solar input cylinders are available in a range of capacities from 180 to 300 litres. They are manufactured from high grade Copper and come with a 5-year Guarantee on the inner container.

ALBION AEROCYLSOLAR INPUT CYLINDERS

PRODUCTCODE

CAPACITY(Litres)

HEIGHT DIAMETER A B C D E F G H& M I JKL WEIGHT(Kg - EMPTY)

WEIGHT(Kg-FULL)

kW RatingLOWER

COIL

kW RatingUPPER COIL

AAUS180C 180 1322 550 135 225 335 355 840 865 915 955 N/F 1057 65 245 22.7 34.1

AAUS210C 210 1515 550 135 225 335 355 905 930 980 1020 1150 1250 68 278 21.5 31.9

AAUS250C 250 1772 550 135 225 335 355 1065 1090 1140 1180 1400 1507 81 331 21.1 33

AAUS300C 300 2096 550 135 225 335 355 1130 1155 1205 1245 1600 1830 97 397 20.5 33.6

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PRESSURE SPECIFICATIONSMaximum Inlet Water Pressure 12 BarOperating Pressure 2.1 BarExpansion Valve Opening Pressure 3.0 BarExpanssion Vessel Charge Pressure 2.1 BarMaximum Operating Pressure 3.0 BarOpening Pressure of T & P Valve 4.0 BarOpening Temperature of T & P Valve 90oCMaximum Pressure on Primary Circuit (Heat pump & Solar Coil) 3.5 Bar

TECHNICAL SPECIFICATIONS

IMMERSION ELEMENT SPECIFICATIONSElement Rating 3kW 240 VThread Type 2 1/4” BSPFuse Requirement 13A via Double Pole Switch

CYLINDER DETAILS & PERFORMANCE SPECIFICATION

PROD

UCT

CODE

WEI

GHT

EMPT

Y

WEI

GHT

FULL

CAPA

CITY

HEAT

UP

TIME

70%

RE-

HEAT

TIM

E

HEAT

PUM

P CO

IL S

URFA

CE A

REA

HEAT

PUM

P CO

IL C

APAC

ITY

HEAT

PUM

P CO

IL kW

RAT

ING

SOLA

R CO

IL SU

RFAC

E AR

EA

SOLA

R CO

IL CA

PACI

TY

SOLA

R CO

IL kW

RAT

ING

Heat

Loss

(kW

/24Hr

AAU150C 57 207 150 Ltr 19m12s 15m40s 2.0m2 1.81 23.3 ---- ---- ---- 1.38AAU180C 61 241 180 Ltr 23m18s 17m06s 3.0m2 2.27 28.3 ---- ---- ---- 1.63AAU210C 64 274 210 Ltr 27m22s 19m18s 3.0m2 2.27 28.1 ---- ---- ---- 1.90AAU250C 77 327 250 Ltr 34m16s 23m25s 3.0m2 2.27 27.4 ---- ---- ---- 2.21AAU300C 93 393 300 Ltr 35m14s 26m10s 3.0m2 2.27 26.7 ---- ---- ---- 2.43

AAUS180C 65 245 180 Ltr 14m35s 10m03s 3.0m2 2.27 34.1 0.963 2.355 22.7 1.63AAUS210C 68 278 210 Ltr 17m52s 12m24s 3.0m2 2.27 31.9 0.963 2.355 21.5 1.90AAUS250C 81 331 250 Ltr 20m08s 14m42s 3.0m2 2.27 33.0 0.963 2.355 21.1 2.21AAUS300C 97 397 300 Ltr 25m23s 17m15s 3.0m2 2.27 33.6 0.963 2.355 20.5 2.43

The Aerocyl’s Copper vessel carries a 5-year guarantee against faulty materials or manufacture provided that:• It has been correctly installed as per this

document and all the relevant standards, regulations and codes of practice in force at the time.

• It has not been modified in any way, other than by Albion.

• It has not been misused, tampered with or subjected to neglect.

• It has only been used for the storage of potable water.

• It has not been subjected to frost damage.• The unit has been serviced annually.• The Benchmark Log Book has been filled in after

each annual service.• The guarantee period starts from the date of

purchase and no registration is required.• The system is fed from a public water supply.

Please note that invoices for servicing may be requested to prove that the unit has beenserviced annually.

All the components fitted to / or supplied withthe Aerocyl carry a 2-year guarantee.

EXCLUSIONS - THE GUARANTEE DOES NOT COVERThe effects of scale build up.Any labour charges associated with replacing the unit or its parts. Any consequential losses caused by the failure ormalfunction of the unit.

GUIDANCE IN THE EVENT OF A PROBLEMIf you have a problem in the first year contact the plumber who fitted the unit. Thereafter contact the plumber who carries out the annual servicing for you. If your Aerocyl develops a leak we will supply you with a new one. We ask for an nominal up-front payment to prevent fraud. We will require the originalunit to be returned to us for inspection along with a copy of your Benchmark Log Book. If it is confirmed that it has failed within the terms of the warranty your up-front payment will be refunded.

If a component part fails within the 2-year guarantee period we will send you a new one without any up-front charge. redit card details may be taken to prevent fraud. We ask you to post the faulty part back to us within one month by recorded delivery.

If you do not return the part we will charge you for it and for the postage and packing. If your part fails after two years service, we will ask for up-front payment.

USER INSTRUCTIONSYour cylinder is automatic in normal use and requires only annual servicing. You should employ a competent installer to perform the annual servicing.

IF WATER IS FLOWING FROM THE SAFETY VALVES THROUGH THE TUNDISH THIS INDICATES A FAULT CONDITION AND ACTION IS NEEDED.

If this water is hot turn the Heat Pump, Solar controller and / or the immersion heater off. Do not turn off the water until the discharge runs cool. The discharge may also stop.

CALL A COMPETENT PLUMBER OUT TO SERVICE THE UNIT.

Tell them you have a fault on an unvented cylinder. We stock all the spare parts they may need (see page 7).

GUARANTEE

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Albion Water HeatersStation Road, Caythorpe, Nr. Grantham, Lincolnshire NG32 3EW

T: 01400 272726 F: 01400 273508 Technical Helpline: 0845 260 7260 Technical Faxline: 0845 260 7261

www.albionwaterheaters.comwww.kingspanhws.com

ALBION IS A MARKET LEADER IN THE MANUFACTURE AND SUPPLY OF QUALITY

HOT WATER SYSTEMS.

MaterialsInner shell - CopperCoil - 22mm Diameter CopperBosses - CopperEvery Aerocyl cylinder is water tested to a pressure of 4.5 bar.

InsulationPolyurethane foam, nominal thickness 50mm.The foam is CFC-Free and HCFC-Free.The foam has an Ozone Depletion Potential of Zero and a Global WarmingPotential of One.

CaseworkZintec corrosion proofed steels throughoutDurable, stove enamelled gloss white paint finish outer casing.AnodeNone fitted/none required

Expansion Vessel12 Litre size with 150 Litre models19 Litre size with 180, 210 and 250 Litre models24 Litre size with 300 Litre models

Control SettingsPressure Reducing Valve - 2.1 BarExpansion Relief Valve - 3 BarPressure and Temperature Relief Valve - 4 Bar/90°CHigh Limit Thermostat in Dual Thermostat - 85°CHigh Limit Thermostat in Immersion Heater - 85°C

Immersion Heater2¼” BSP Parallel Threaded HeadLong Life Incoloy Sheathed Low Noise Element 14” LongLong Life Incoloy Sheathed Thermostat Pocket 11” LongBrazed ConstructionCombined Thermostat and Safety Cut-OutElement Rating 3kW at 240V A/CApprovals

KIWA Approved to Building Regulations G3 & LCE Compliant and fitted with a BEAB ApprovedImmersion Heater

Specification summary...Albion Water Heaters, part of Kingspan Group, is a majormanufacturer of Domestic Hot Water storage systems in the UK and offers the trade products backed by the service and technical development skills that only a company of its size can.All sites are licensed to British Standards quality assurance BS EN ISO 9001 : 2008 and Albion is a BSi registered firm. This means that all manufacturing plants are monitored by an independent inspectorate and the quality systems employed by Albion meet the stringent requirements set down.Specifiers, stockists and users can depend on Albion forconsistent quality and supply. Albion continues to developenergy saving and innovative hot water products for domestic and commercial applications.Contact information:Albion Water Heaters, Station Rd, Caythorpe, Grantham, Lincs, NG32 3EW

Kingspan Renewables have a policy of continuous product development and may introduce product modifications from time to time. As a consequence details given in this brochure are subject to alteration without notice.

OHSAS 18001

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Kingspan Renewables: A trading name of Kingspan Hot Water Systems Ltd. Registered Office: Tadman Street, Wakefield WF1 5QU. Registered in England, No. 04357772